Refining catalyst laden hydrocarbons



Jan. 5, 1954 E. w. HOWARD ETAL REFINING CATALYST LADEN HYDROCARBONS Filed Nov. 30, 1950 Patented Jan. 5, 1954 REFINING CATALYST LADEN HYDROCARBONS Everett W. Howard, Glen Rock, and John B. Osborne, South Orange, N. J., and Henry P. Wickham, Upper Brookville, N. Y., assignors to The M. W. Kellogg Company, Jersey City, N. J., a

corporation of Delaware Application November 30, 1950, Serial No. 198,376

4i Claims.

This invention relates to an improvement in the rening of the products of a catalytic hydrocarbon conversion process, and more particularly to the refining of the catalyst-laden products of a fiuidized hydroforming process.

Part of the subject matter disclosed herein for completeness is not our joint invention and is described and claimed in the concurrently iiled application Serial No. 198,375, led November 30, 1950 of Everett W. Howard.

An object of the present invention is to provide an improved method for reiining the products of a catalytic hydrocarbon conversion process.

A second object of the invention is to provide an improved method of refining the elrluent from a catalytic hydro-forming process.

A third object of the invention is to provide an improved method for the recovery of entrained catalyst nes from the reaction products of a fluidized catalytic hydrocarbon conversion process.

Other objects of the invention will in part be obvious and will in part appear hereinafter.

This invention concerns condensing a highboiling normally liquid fraction of the products, using this condensate to scrub entrained catalyst fines out of the remaining products, settling the resulting slurry, decanting a catalystfree portion of the settled slurry, stripping relatively low molecular weight compounds from the decanted condensate by reducing the pressure and by contact with a gasiform stripping agent, and recovering said low molecular weight compounds by separating them from the stripping agent. In another aspect, it also contemplates returning catalyst nes to the reaction bed in the form of a relatively concentrated suspension in the high-boiling condensate.

The invention accordingly comprises the several steps and the relation of one or more of said steps with respect to each of the others thereof, which will be exemplified in the process hereinafter disclosed and the scope of the invention will be indicated in the claims.

Many advantages result from the present invention, as will be apparent to those skilled in the art from the appended description. By settling and decanting the initial high-boiling condensate or polymer, a smaller quantity of heavy hydrocarbons is employed to return catalyst lines to the hydroforming reactor thereby minimizing the deposition of carbonaceous materials in the reactor from this cause. More-over, an excellent separation of gasoline range components from 2 the polymer stock is procured by flashing this material while stripping it with a suitable gas or vapor. The recovery of gasoline constituents is further enhanced by absorption in the naphtha feed of the'overhead gas from the polymer flash tower as well as product gas separated from the normally liquid constituents of the hydroformate.

Although the invention is specifically described in conjunction with hydroforming with a iluid catalyst, the present rening process is of broader scope and is readily adaptable to other relatively high pressure petroleum processes employing a finely divided contact material. For instance, it may be used in connection with hydrodesulfurization, hydrogenation, cracking or hydro-cracking (cracking in the presence of hydrogen) with iiuid catalysts, continuous fluid coking operations and the like where the reaction products are under a pressure of at least 50 and preferably above 100 pounds per square inch gage (p. s. i. g.) in order to permit :dashing the high boiling initial condensate.

The invention is best understood by reference to the accompanying drawing in which a hydroformer and associated refining equipment of 7500 barrels per day (B. P. D.) capacity are schematically depicted.

86,070 pounds per hour or '7515 B. P. D. of fresh naphtha of 48.5 API gravity are pumped at F. through line 2 into the top of absorber 4 where this naphtha is used to scrub most of the 4-carbon and al1 of the higher hydrocarbons out of that portion of the product gases which is not recycled to the hydroforming reactor. 88,828 lbs/hr. (7800 B. P. D.) of enriched naphtha with a gravity of 49.8 API leave the bottom of the absorbing tower at 410 F. and 85 p. s. i. g. through line 6. A pump 8 in the same line feeds the fat naphtha to combination furnace l0 in which it is heated to a temperature of 990 F. and exists through line l2. 4120 mols per hour (M. P. H.) of recycled product gas, from a source to be described later, are heated in a separate coil in the same furnace and leave it at 1100o F. through line I4.

The preheated naphtha and recycle gas are commingled in pipe IS and fed through a conventional inverted cone and grid distributor into hydroforming reactor I8 at the bottom. This Vhydroformer is a vertically disposed cylinder extending 701/2 feet between the knuckle radii and having an internal diameter of 12 feet. It is lined internally with 41A, inches of refractory insulation of a conventional type. From the distributing grid located at the lower knuckle ra- Screen Weight, Mesh percent 100/140 1-1. 5 140/200 42. 0 200/325 25. 5 S25/pan 21. 0

The average superficial velocity of the reactants is 0.42 ft./sec. and the space velocity is 0.4 pound of naphtha per hour per pound of catalyst in the bed. Since the catalyst bed is in turbulent mor tion like a boiling liquid, temperature variations therein are minor and the average bed temperature is 940 F. Near the top of the bed a slurry of catalyst nes in polymer is introduced through line 20 from a source to be disclosed hereinafter. In the upper part of the reactor the gasiform reaction mixture leaves the dense phase catalyst bed which has a density of 39 lbs/cu. ft. under normal operating conditions,r and passes through the interface 22 into a disengaging Zone about l5 feet high in which the gas contains only a very small quantity of entrained catalyst. The reaction products leave the disengaging zone at 930 F and 500 p. s. i. g. through internal cyclone 2,4 and pipe 26. Cyclone 24 separates most of the entrained catalyst fines and these are returned to the dense phase by dip, leg 28 which projects down below the surface of the reaction b ed.

As the hydroforming reaction proceeds, the nely divided catalyst is continuously being with,- drawn and added to the reaction bed at rates which differ only by the quantity of carbonaceous deposits on the withdrawn catalyst..Y Thel partially spent catalyst which is. withdrawn isfre-` generated by combustion` with oxygen-containing gases and the regenerated` catalyst is recycled to the bed at the rate of 7530 lbs./hr.,l giving' a catalyst to naphtha feed ratio by Weight of 0.088. In view of this extremely small circulation of catalyst to and from regenerator 30; the catalyst in the hydroformer contains avsubstantially uniform quantity of deposited carbonaceous matter and absorbed hydrocarbons and is therefore of substantially uniform activity throughout the depth of the bed. The 21/2 inch spent catalyst transfer line 32 has several valvedbranch lines 34, 36, 355 and 40 of the same size which communicate with drawoff wells 42, 44, 46 and 48, respectively, in the conversion bed. This permits withdrawing the catalyst at one or more selectedlevels in the bed in order to avoid any possibility of stratification of the catalyst. In pipe 32 the average fiow of partially spent catalyst is8372 lbs/hr.

at an average velocity of 2.2 ft./s`ec. and a density of 39 lbs/cu. ft. At the inlet of valve 50 the pressure is 516.1 p. s. i. g. The normal pressure drop across safety valve 50 and control valve 5,2v amounts to 6.4 p. s. i. Four lbs/hr. of steam or other suitable aeration medium are admitted to transfer line 52 immediately above valve 50 and at higher points along the line to maintain the catalyst in an aerated condition. The transfer line is also tapped above and below Valves 50 and 52, respectively, to provide pressure connections for a differential pressure controller which operates to close the safety valve 50 whenever the pressure drop across the two valves is less than 3.0 p. s. i. This prevents any backflow of regeneration gases from reaching the hydroforming reactor I8. Although valve 52 may be arranged for` automatic control in response to any suitable reaction condition, it is preferred to have this valve manually regulated by an operator in respense to the carbon content of the partially spent catalyst in line 32 from which samples are withdrawn by. means (not shown) at regular intervals for carbon analysis. It is reommended that the coke or carbon content of the catalyst in pipe 32 he maintained at about 5.0 percent by weight.

The regenerator 30 consists of three sections designated 30A, 30B and 30C. The lower section 30A is a steel shell of 4% feet I. D. which extends upward 5 feet and then tapers inward for the Upper 5 feet of its height to I 8 inches O. D. Vessel 311Av is lined with 41/2 inches of a suitable refractory material adapted to withstand the 1100" F. temperature of the combustion zone. Tube 30B is 47 feet long and of 18 inches O. D. and has an internal cross sectional area of 1.15 square feet; stainless steel is preferred as the construction material here. Above it is separating or collecting vessel 36C which contains the upper dense phase bedv of the regenerator. This unit comprises a 4 foot tapered section connected to carrier line 30B and surmounted by a 20 foot cylindrical steel hopper chamber of 9 feet I. D. and a settling chamber of 3 feet greater diameter which has an; effective length of 17 feet up to the upper knuckle radius. The entire vessel 30C is lined with a 41/2 inch thicknessy of internal refractory insulation.

or other suitable porous materials are provided.

If desired,V suitable cyclones, multiclones or other suitable separation equipment may be substituted. The pressure in the regenerator at the distribu tion grid (notshown) in vessel 30A is 510 p. s. i. g. and pipe 32 is connected thereto at apointY where the pressure is 509.7 p. s. i. g,

Air forregeneration is supplied to combustion chamber 30A under aV suitable pressure at the rate of 10,654 lbs/hr. orf370 P. H. via line 5S and recycled flue gas is introduced into the same feed line at the rate of 79,200 lbs/hr. (2G00 M. P. H.). This iiue gas has been cooled to 650 F. and serves to dilute the regeneration air to an oxygen content of 4.27 mol percent in order to maintain the regeneration temperature atabout 1100 F. by this dilution. Temperatures above 1150or F. are undesirable as they tend to permanently' deactivate the catalyst. In general, temperatures of from about 750 to about 1150 F. are suitable for regeneration of the catalyst and the rangefrorn about 1050 to 1100 E'. is preferred for the purpose. Control of the regeneration temperature is effected by regulating either the quan-v tity of cooled flue gas recycled to vessel 30A pref# erably or otherwise the aii supply in response to the demands of a temperature controller (not shown) with an element located in the combustion chamber. Thus, an excessive regeneration temperaturel isy brought within the desired To separate the re-4 limits by further opening of the valve in flue gas line |06 to cool the regeneration gas to a lower temperature or alternatively by throttling the iiow through a valve (not shown) in air supply line 58 to reduce the oxygen content of the regeneration gas. Insufcient regeneration temperatures are increased to the normal operating range by automatically operating one of the valves mentioned to decrease the Supply of cooled flue gas or increase the air supply. With the regeneration gases passing upward at 2 ft./sec. the density is 20 lbs/cu. ft. in the lower section. While not moving upward at the gas velocity in the lower or main portion of combustion chamber 30A, the nely divided catalyst particles are in dense phase suspension in the regeneration gas and are displaced slowly upward as more spent catalyst is received near the bottom of the chamber from line 32. As the powdered contact material travels up into the conical section of the chamber its velocity gradually increases due to the decreasing cross section of the conduit and the density of the mixture gradually decreased to a relatively dilute suspension as more and more of the catalyst is entrained in the gas. Substantially all of the catalyst is entrained and moving at a relatively high speed, but lower than the superficial gas velocity by the amount of slippage before the inlet of carrier line 30B is reached. Far less erosion is encountered in this gradual acceleration operation than in the usual case where powdered catalyst is merely dropped into a gas stream flowing at a high velocity. In addition, substantially less catalyst attrition to particles of undesirably small size occurs and the 0 bumping or vibration commonly experienced with high velocity carrier lines is eliminated. These results may be accomplished by maintaining the superficial gas velocity in the widest part of combustion zone 30A at about 0.3 to 5.0 ft./sec. and the catalyst density between about 15 and 42 lbs/cu. ft.; however, the preferred ranges are 1.0 to 3.0 ft./sec. and 15 to 30 lbs/cu. ft.

In tube 30B, the powdered catalyst is carried upward at the comparatively low density of about 1.0 lbs/cu. ft. by the gas moving at a supercial velocity of 23 ft./sec. Under these conditions, little variation in pressure exists in tube 30B, where the pressure at the bottom is 508.8 p. s. i. g. and the pressure at the outlet is 508.1 p. s. i. g. The principal function of this section of the regenerator is to conduct the catalyst to a point sufficiently elevated to permit return of the regenerated catalyst to the hydroformer by the gravity head or luistatic pressure developed by the catalyst. Combustion of the deposits on the catalyst is usually complete in regeneration chamber 30A, but no harm results if the combustion reaction continues in carrier tube 30B or the .separation section 35C. The supercial gas velocity in carrier line 30B may vary between about and 50 ft./sec., or higher where erosion is no problem, with catalyst densities ranging from about 0.1 to 10.0 lbs/cu. ft.; the preferred ranges being l0 to 30 ft./sec. velocities and 0.5 to 10.0 lbs/cu. ft. densities.

In the upper bed within vessel 30C, the velocity decreases as the cross section increases in such manner that the velocity is 0.5 ft./sec. and the density is 37 lbs/cu. ft. in the main portion of this section. The catalyst particles of course slow down upon reaching the bed and most of them drop out of entrainment in the flue gas. This is a bed of comparatively high density, therefore, a moderate fiuistatic or gravity head is developed. Here the pressure decreases from 506.7 p. s. i. g. at distribution plate 54 to 501.6 p. s. i. g. above the interface 60 which is usually maintained at the level where the regenerator begins to widen out to form the settling section of chamber 30C. Due to the enlarged cross section the superficial gas velocity drops further to 0.27 ft./sec. which causes much of the small amount of catalyst still entrained in the iiue gas to separate therefrom. In the bed and the disengaging zone thereabove, over and usually above percent of the catalyst is separated by gravity alone from the low velocity gas stream. The supercial gas velocity through the bed in vessel 30C may vary from about 0.3 to 2.0 ft./sec. and catalyst density from about 20 to 42 lbs/cu. ft. with the presently used hydroforming catalysts; however, limits of 0.3 to 1.0 ft./sec. and 30 to 39 lbs/cu. ft. are recommended. The range of suitable gas velocities and catalyst densities for reactor I8 is the same. In this connection, it is Well to note that the density of the bed must be coordinated with the depth and elevation of the bed to provide a sufcient uistatic head for return of catalyst to the hydroforniing reactor. There is no substantial variation of the regeneration temperature from 1100" F. in any of the three principal zones of regenerator 30.

The regenerated catalyst which accumulates in 30C is returned from the bed in which the pressure is 506.7 p. s. i. g. through draw-off wellf62 down the 21/2 inch transfer line 64 through safety valve 66 and control valve 68 into the lower portion of reactor I8. The point of entry into the hydroformer should be spaced 90 degrees from any draw-olf well therein at approximately the same level in order to avoid short-circuiting of the regenerated catalyst to the spent catalyst draw-oft` well. Air or another suitable aeration medium is introduced into line 64 at the rate of 3 lbs/hr. to maintain the catalyst in a uidized state in order that a gravity or fluistatic pressure head may be developed in line 64 whereby the pressure is raised from 506.7 to 519.9 p. s. i. g. immediately above valve 66 when the density in line 64 is 39 lbs/cu. ft. This provides the pressure necessary to overcome the 5.4 p. s. i. pressure drop across valves 66 and 68 and introduce the catalyst into the hydroformer against a pressure of 514.5 p. s. i. g. Under average conditions 7530 lbs/hr. of catalyst pass through transfer line 64 at an average velocity of 2.0 ft./sec. The velocity of the dense phase catalyst in transfer lines 32 and 54 should be kept below about 8 ft./sec. to minimize erosion of the slide valves in these lines. For most of their lengths, these pipes must be inclined to the horizontal at an angle greater than the angle of repose of the aerated luidized solids in order to maintain a smooth steady flow of catalyst. Generally the angle must be at least 30 degrees but angles of 45 degrees or more with the horizontal are recommended. Short sections, say several feet, of these transfer lines may be inclined less or even horizontal, but this practice is not recommended as the aeration gas tends to separate from the solids at such points. Valve 66 is a safety valve which operates similarly to valve 50 in response to a conventional pressure differential controller (not shown) to shut off the flow of catalyst and prevent back ilow of hydrocarbon gases from reactor to regenerator section 30C whenever the pressure drop across valves 66 and E58 is less than about 3.0 p. s. i, In routine operation the ow of catalyst isentirelycontrolledrby.valve' 68;-which like valves 50,252 fandlr`66, .Iis'iaslide-valve- This valve'i` may befautomatically icontrolledf'lnresponse to fluctuations of yfa. selected :reaction condition,and1it1-is preferred to operate this lvalve .in Lresponse alto fluctuations innthe level of interface. '.This-is accomplishedvby adiirerential pressurecontroller Inotrshovvn) provided 'WithrV pressureconnections tof,pointssabove.andibelowlthezlevelshown. :This

controller operates to freduce V4the ow through valve-168 fwhenthe: levelr lin thexupperzbedof vessel 30C Ltends to drop vbelow the levelrshown :,atr andato open valve 168- more when the .level rises above that shown in the drawing.

It will bei observed .that `the'system.'described hereincirculates catalyst through'theA reactor; to regenerator transfer linev 32 and 4the.regenerator to reactor return line 64 solely byl balancing static pressures, including gravity or 'uistatic Ypres-- sures, Vin Y. the wsystem. `Thus, the. partially' spent catalyst is .transferred iby Ygravity ''alone i or4 aided .by a small `pressure differentialn tothe regenerator where the regeneration gases reactivate: lit Iand carry it to the upper'bedin section-SUC-frorn whichv it lis returnedbyfgravity'above-to a zone ofsomewhat higher pressure in hydroformingreaction bed. Thus, the :Contact material isnever in contact with anypump or-other devicecontaining moving parts. LIhisis=very-desirable,- inasmuch-Ias the ContactA materiaLis-of a highly abrasveinature. "The Aeffect f theforce ofigravity in developing. 'iluistatic orvv-pseudo-liquid pressures inbeds Y and columns of .aerated powdered catalyst islwlllknown '.In the present system such pressures are obtained by.' locating various eleinents'of4 the' hydro'forrning system at' the relative elevations listed-herinbelow.

''TaZe'I ARegenerator 30: `Elevation irl-.fectvabove-'dctum plane Combustion" chamber 30A- l liwer knuckle radin "Il (datumplane y5 Bottom 4 y10 `Top I*57 Separation chamber '30C- Lower knuckle radius 54..... .6l Interface 60 #El Upper knuckle radius 9B Reactor 18; v v

=L\vcr\'knuckle radius 8 Inlet-ofline 6=1 10 Interface 22 63% Upper knuckle radins 78% 'llo maintain-the controlledpressures inthe catalyst -circulatory system,v a differential pressure controller' 'mis provided which vis connected to the tops .f -the-regeneratorand the reactor. Pressure controller`l0 regulates' the pressure differential between these two vessels by controlling the passage'ofh regeneration flue gas' through. regulating valve'IZ in exhaust line-14. l i

'Where it is desired to'e'in'plo'y alluidizediconversion catalystother than'that Idisclose'diherein, suitable adjustment f gas velocities, y"densities, equipment elevationsforstatic pressures at lvarious points'may bema'de 'accor'ding"to"'the 'principles of the" present invention tomaintain' the catalyst c1culation"required for theparticular catalyst.

In cases where the catalyst circulation rate is lowfstrpping of either the partially'- spento'r the regeneratedcatalyst is not:consideredworthwhile However, 'means for `stripping 'the deactivated contactmaterial incither one-or more-'f ithe draw-off "wells" in reactor I-8 or inaseparate vessel with "steam, recycled 'product'gas vprettier suitable medium'mayibe vreadily installed. The regenerated catalyst maybe similarly -Vstripped 8 wlthfsteam, absorben tall- `gas` `or other appropriate'strpping' uid.

'Thef regenerationfgases leave the '.disengaging or settling l-Zone "at the Etop of -l chamber --30C through Lpo'rous'lters 1#56 which i remove all fentrained #catalyst fines from lthe dilute rphase. From thelters, these iluelgases passthrough pipes ."lflandipas'sa'ges in 'automatic time fcycle controller "le, -of known lconstructiom into v.line 80. ."As Mline particles buildupfon?V filters 256". they gradually 'restrict owthro'u'gliithe lters fhence, it. isn'ecessa'ry toblow Vgas.:bachithrough 'the-'fzlters occasionally Lto preserve their "filtering efficiency. '.This blow-back operatlon' withil'ue gas from.` line 182 l.ismgoverned .'by the "-valve arrangementinicontroller'I8.. in f'suchmanner' as'toblow gasbackward through each ofwt'he iltersllnssequence. It isrrecom'mended:thatwhile one'lter is Abeingclearedby sblowba'ck atl anyv given instant; the remaining lltersfcontinueLtoflter .the regeneration; ue Vgas. ILinea' conducts 110,'344 lbs;/ hr. (3521 MQRJHJ :lof '.'regenerationfgas vIto wastefiheat f boiler 84 '1 where .the temperature of the flue gas .is loweredfrom `11'00.F. Ato 650- F. Infgivin'g upthisl`heati13g500 lbs/hriof water at 240 Pfand '525"p.fs...i. g: from ydrum BS'isconverted into `3525.1). s. i.g. steam. The cooled'flue gas leavesthe.boiler'inline 88, and4344 lbs/hr. of this gas ontheaveragelis 'echausted from'the system via 'valve'lZ in line-14.

'Thef remainder :of the-'relatively cool fiue gas passes throughl pipes88,'90 :and 92f-to lcompressor 94 which Araises the pressure Iffrom v 4195 'to about S25-ip. s.1i.1g. 'Inthefevent'ofr'breakageof one of the'flters '256, v compressor '594 `would probably beisubjecte'd lto `extreme vwear .by y abrasion from the'. catalyst fines inl thel fluelgas .passing through this vvcompressor. Y"To 1 preclude? this,l an auxiliary filtering apparatus 96 is lprovided i for -justlsuch emergencies. In thiscase,1by suitable'manipulation of the valvesin lines 90 and=58, fluefgas would hei'drectedffrom pip'ei`88 Ithrough line 298, filtering apparatus "-'96A and line -IUB to pipe 92. Pipe 2 I e2 is providedlto `supply fhighpressureair, fromia'isourcei'notshownfor'clearing .the llterrin tankfe Iby blot/#back 'therethrough iThelflue `gas leaving '.cor'npres'sor 94 'via `line vIIlll contains 129 vmol 'percent lof oxygen vand I.is 'divided Abetweenlines ''Ilr and? |08. '-Pipe Imi carries 7 9,200 lbs/hr. (2600'1M. 1P. H.) 'to theregeneratoriair supply line158 fromwhichthe -gas enterstheI regeneration tow-er 30. fLine! Hi8-conveys 'theblowback lportion lof" thefrecycleilueV gas through blowback i heater I I -vtheife ,the temperature -iof .the 'gases is raised 'Ito 1100 TF. in vorderllto .minimize thermal stresses v1in 'fllters l=5I5 in i the lblow-back operation. -`From1 thisheatergthe stream of blowbaci: fgas, *Wh-ich amounts Ito `191800 v1bs./hr.1.is carried throughline 382.1;0 the-blow'back valve system'-.

vReturning "nowf to'the products of the hydroforming 'reactionjlinefcarries a mixture of gases, vhydrocarbon vapors and entrainedcatalystfflnesat 930 Fjto'heat exchanger i I2 where it -is cooled to 780?. `Thiseluent has a molecular Weight of 31.1 and consists of-I71620 lbs/hr. of gases and vapors, 'inaddition to the '630 lbs/hr. of'nes entrainedtherein. Fromheat exchanger l I2the eluent passes throughrline I Mito-the scrubloerfractionator1 I I6. This' piece ofequipmentfcontainsan upper fractionation section 'I I`I BAv fv conventional bubble. plate-construction with ten plates. The midesectionA I IBB consists of :ascrubbingtsection in whichfall of the catalyst fines fare scrubbed :out by passage through curtains of the polymer liquid falling from one to another of the iive inclined baiiles in this section. At the bottom of the tower is a decanting or settling section I |6C where the solid iines are settled out of the slurry descending from the scrubber above. The reaction products and fines are introduced from line H4 into the bottom of scrubber section HEB where the temperature is maintained at 575 F. and the pressure at 495 p. s. i. g. Only polymer is condensed out of the incoming gases in scrubber UBB for the temperature at the top of this scrubber is 505 F. This crude polymer is composed chiefly of branch chain aromatics along with about l5 percent by weight of gasoline or lighter materials. It boils well above the gasoline boiling range which is considered Vherein to extend from 100 to 400 F. at normal atmospheric pressure.

For the purposes of the present invention thew high boiling condensate used to scrub the catalyst nes out of the Ahydroformer products may have a gravity of from about 5 to 25- APLand--a boiling point from about 400 to 700 F. at atmospheric pressure at the time of leaving the bot- Y' tom of scrubber iliiB. For best results, this liquid effluent from the scrubber should have an API gravity between about 12 and 18. In the fractionator ||6A the temperature drops from 505 F. at the bottom to 370 F. in the eiiiuent gases passing through the overhead line I8; and here liquids having gravities of 30 to 45 API are condensed. 27,500 lbs/hr. of light liquid products (67.8 API) are introduced into the top of tower HSA at 100 F. from line |20. The source of this reux liquid will be described hereinafter. From the bottom oi the fractionator section |6A, 12,160 lbs/hr. of an oil with a gravity of 38.0 API is withdrawn through line |22 and pump |24. The stream emitted by the pump is divided equally between lines |26 and |28. The material passing through pipe 28 is cooled from 505 to 120 F. by cooler |30. The efuent from cooler |30 is passed via line |32 to various pumps used in the refining system. It is used as a high pressure lubricant and returned to the top of scrubbing section ||6B in line |34. The oil in pipe |20 is employed as a high pressure iiushing oil.

for `the bearings of pumps |36 and |38 to prevent the catalyst fines in the abrasive Slurries` passing through said pumps from contacting friction surfaces of the pumps. This flushing oil passes to the interior of the pumps and joins the liquid being pumped therethrough. 3,040 lbs./hr. of`this oil is supplied to each of the pumps. From the bottom |40 of scrubber` HGB, the slurry of catalyst in the polymer (15.0 API gravity) is withdrawn through line |42 and split between pumps |33 and |38. 165,400 lbs/hr. of 15.0 API polymer along with 10,000 lbs/hr. of the catalyst fines is forced through line |44 to the reboiler |43 where its temperature is reduced from 572 to 425 F. The slurry returns to the top of scrubber ||6B in pipe line |48.' while, 145,000 lbs/hr. of polymer plus `8750 pounds of solid nes are pumped by pump |38 viaJ line |50 to a diierent reboiling heat exchanger l52. Here the temperature of the slurry is dropped from 572 to 475 F. and the cooled slurry is recirculated to the scrubber in line |54. i

All the catalyst iines are scrubbed from the hydroformer eiiluent gases by polymer condensing in section iltB. for substantially all of the 38.0

API fraction condensing in fractionator ||6A is returned to the scrubber in tower H5 whereall of its lighter components are vaporized land Meann passed overhead. From the bottom |40 of scrubber ||6B, a portion of this catalyst slurry descends into settling section HBC where the catalyst settles to the bottom and a thickened slurry of high solids content is drawn ofi in line |56 at the rate of 5460 lbs/hr. of the polymer along with 680 pounds per hour of catalyst at 575 F. and is returned to the hydroformer IS by means of pump |58 and line 20. From the upper part of the settling section, a stream of polymer free of the catalyst is removed from draw-off well |60 and passed through pipe |62 containing regulating valve |63 to the six-tray polymer flash tower |54 at the rate of 5810 lbs/hr.

The gasiform mixture taken overhead in line ||8 at the rate of 257,850 lbs./hr. (6602 M. P. H.) has a molecular weight of 39.0. An increase in the molecular weight over the hydroformer effluent., will be noted as a result of recycling the light liquid products in pipe |20 to the fractionator HBA. This overhead fraction is passed -through heat exchanger |66 and cooler |68 to reduceits temperature from 370 to 100 F. on its way to separating drum |10 which is maintained at 480 p. s. i. g. The water and liquid hydrocarbons condensed in cooler |68 are separated from the remaining gases in separator H0. Water is drained off through line |12 at the rate of 84 lbs/hr. and the liquid hydrocarbons are withdrawn through line |14. These hydrocarbons are divided and the major portion is returned to the fractionating section ISA as reflux via pipe |76, pump |18 and line |20. The somewhat smaller remainder of the 67.8 API liquid hydrocarbons continues along line |74 at the rate of 74,096 lbs/hr. and is reheated by heat exchanger from 99 to 317 F. which converts the stream into a mixture of liquid having a gravity of 60 API and vapor of 50.0 molecular weight. From pipe |82 this mixture is introduced via regulating valve |83 into the middle of a :S0-plate stabilizer |84. The feed to the stabilizer consists of 12,500 lbs/hr. (250.0 M. P. I-I.) of vapor and 61,596 lbs/hr. of the liquid. The liquid descends down the plates of the stabilizing column with a gradual increase in temperature and is withdrawn from the bottom plate through line |66 at 385 F. as a 63.5 API liquid at the rate of 140,430 lbs/hr. and passed through reboiler |52 where it is converted into 75,000 lbs/hr. (930 M. P. H.) of vapor having a molecular weight of 80.8 and 65,430 lbs/hr. of a 52.0 API liquid. This mixture is reintroduced into the tower via line |88 below the bottom plate where the temperature is 433 F. and the pressure is 295 p. s. i. g. All of this vapor passes up the tower. and all of the liquid is drained off through pipe |90 and passed through heat exchanger |80 which reduces its temperature to 170 F. and cooler |92 which further cools it to F. This product is stabilized gasoline and is conducted to suitable storage facilities. The vapors ascending the ltower are partially condensed and the overhead leaves at F. at the rate of 47,666 lbs./hr. (1120 M. P. I-I.) in line |94. Cooler |96 reduces the temperature of the overhead to 100 F. to condense its heavier components and the material is conducted by pipe l |98 to separator 200 where the pressure is maintained at 285 p. s. i. g. 39,000 lbs/hr. of liquid having a specific gravity of 0.506 is separated here and refluxed to the tower through line 202, pump 204 and pipe 206. The stabilizer gas has )a molecular weight Yof 35.5 and is withdrawn through-line 20.?at the rateofSfliisjhr.-v (243!! M; P. H.) vas.` a'productiofgthe-:processr Returning nowi'to separating' drinn 110;.L the gas withdrawninl line 2.o! agtfthe-g rate 0121,86 ,170 lbs./hr.1 (#1564.v P; H.) is; dividedintdthree streamsy One of the ystreamsiis. passedthrough line 212 .to accumulator 2 I4. Thisportionni the gas Visi-recycled via line 2 165 compressor v2.18; back tothe -hydroforming ,reactor at therate of v'T7-,790 lbs/hr.- (4120 M.YP HD. This-gas has amolecular-weight of 18.9 andcomprises essentially-flight hydrocarbon gases and vapors with a concentration of4 29.2. molpercentof hydrogen.v After passing throughline 220, the-temperature of the recycle gas=is-raised from l120 vto 330 F. byvheat exchanger |66; It then is conducted through pipe.- 222 -and heatexchanger I l2 where. its temitflsconverted into-,52;00o;lbs=/hr. (566;Mf, Pf H0. offvapor;v having`v a molecular; weight of i 91.7 and 88,828.1bs./hr. of aliquid of Y49.8 API.. gravity. The-.vaporf-and :liquidarereturned to the tower through line 244: I nthetower, vall lof V,this liquid, which consistsgof naphtha, enrichedv by absorbed gases;` leaves the bottomV inlinef 6 as described previously. Theiabsorber tail gas 4goesoverhead in* line-` 246 at aT rate of. 6511v` lbs/hr. (4.10 M.VP.H`.); It hasanaverage moleculaiweight of 15j.9:a nd chiefly consistsof hydrogen and meth-.- ane .-as a; by-product ofV the process. This gas is customarilypassed to storage; tanks and, employedeithcr as a fuel or'process gas.

Yields from the operation 4ofthe `hydroforming unit described above are ,summarized in standard terms inthe .table below:

perature.- is further boostedto 705*F1 Thereafter; this'gasis conducted through line'224 to the furnace Iii andits temperature israised 'to 1100'F. This recyclegas leavesthe'furnace in line hito, entertheihydroforrner feed line as previously described:

A second portion o the gas in line 210 is drawn oir by line 223 Aandl passes through the reducing valve 223 and line 23B on its way to the absorber Il lwhere the pressureV is yconsiderably lower than indrum |10. The remainingsmall portionk of gas, 290 lbs;/hr. (15.0 M. P. HJ, passes fromi line 2lll'throughpipev 2321 and reduc-ingvalve 234 to the polymerash tower 164 whereit servesv` to strip the gasoline andvlighter componentsfrom the 15 API polymer being lflashed into the tower. from line 162. The bottom othe tower is main.- tained at 85p. s. i. g. and 515 F.' and the-de'- scending polymer increases in` gravityv until it leaves through line '236' at'the rate of 4750 lbsr/hr'. (330 B..P. D.) and agravity of 12"`APIL` This material is runthroughcooler 238,011 its-Wayrto storageV tanks and thereby cooled'vv to 125' F; Vaporsileave. theY top-V of flashv tower |64 atthe. rate-of1350 lbs/hr. (32M: P; H.) and temperaturev of 530 F.' ini line240, which joins the 8089 lbsz/hr. ofplighter gases fiowingthrough-line 230: Alternatively; the light fraction may bestripped outof the crudepolymer by introducing steam into theA bottomiof'tower |64'. In this-case',- a condenserinot shown) is-installedin line-240 to condense boththeA steam andthe stripped hydrocarbons which'have an average gravity of" 251 to 40 API." This hydrocarbon fraction containswell over 50 percent aromaticsyhence; it, is: drawn oi'; separately. from. the: aqueous. cone densatei andi pumped to; gasoline storage :,tanks;

The hydrocarbon mixture ini pipe;- 2 3 0; has a.,

trays. and the gas inlet.is located below the 18th. trayfrom thetop. Fromthe bottom tray of the` stripping section; the enriched naphtha is withdrawn'at the rate of 140,828 lbs/hr. with a' temperature of-290QF. through'line 242 This59.4 API-'liquid f isfpassed through` reboiler l 1E-where The catalyst inventory for the. system is tons. Hydrogen production amounts to 162 cu. ft./bb1. naphtha,y charged andkr the.v recycle gas. rateis 5000. ou. ft./bbl; of naptha, the glas volumesboth being measured at' 60 F. and 760 mm. mercury pressure. The regeneration air is present in a reasonable excess. over tl'iat'required to regenerate the catalyst'since it was calculated on atotal carbon equivalent of 1.04"weight percent. The lean oil loss ofl lbs/hr. of naphtha by evaporation from the toptray of absorber 4 is not included'in` the stated quantity of 'absorber tail gas although the gas, actually includes this vaporized naphtha.

Since certain changes maybe made in carryingoutthe above p rocesswithout departing from the scope of the` invention., it is, intended that all'material contained in the above description.

tactedwith a massfof. finely divided solidsin .areaction4 zone and. the.. reaction products. thusv produced. are` separated substantially from, saidmass or solids` and thereafter contain. a. small amount of entrainedsolidnes relative tothe quantity.r of solids presentin the reaction zone, the improvement. which.comprises cooling. the hot. gasiform, reaction. product. and, entrained solid fines. tQcOndensea major portion of high, boiling normallyy liquid products, scrubbing. the,v

solidiines ,outoi uncondensed gasiform products,

toiorm. aslurry, settling said `slurry, decantingv,

a substantially. solids-'freepprtion of thevhigh boiling condensatefrom the settled slurry, cooling. the uncondensed., gasiform products suinciently to condense a major portion of relatively lower boilingv normally liquid products therefrom thus leaving uncondensed normally gaseous. products, stripping lower boiling normally liquid products from the' decanted high boiling'conf densateA by reducing the pressure andp by-contacting the same with a portion of normally gaseous products* wherebyk the latter products i3 are enriched, and contacting the enriched normally gaseous products and another portion of the normally gaseous products with the liquid hydrocarbon feed material for the conversion process to absorb therefrom relatively lower boiling normally liquid products by absorption.

2. In the refining of the products of a contact process for the conversion of hydrocarbons wherein a gasiform hydrocarbon material is contacted with a mass of nely divided solids in a reaction zone and the reaction products thus produced are substantially separated from said mass of solids and leave the reaction zone containing a small amount of entrained solid fines relative to the quantity of solids which is present in the reaction zone, the improvement which comprises cooling the hot gasiform mixture of reaction products and entrained solid fines of contact material sufficiently to condense a major portion of high-boiling normally liquid products, scrubbing solid fines out of the uncondensed gasiform products by contact with the high-boiling condensate to form a slurry, settling said slurry, decantng a substantially solids-free portion of the high-boiling condensate from the settled slurry, cooling the uncondensed gasiform products suiciently to condense a major portion of the normally liquid products therein, stripping relatively low molecular weight compounds out of the decanted high-boiling condensate by reducing the pressure thereon and by contact with a portion of the normally gaseous products whereby the normally gaseous products are enriched, and contacting the enriched normally gaseous products with the liquid hydrocarbon feed material for the conversion process to absorb therefrom the low molecular weight compounds.

3. In the rening of the products of a catalytic hydrocarbon conversion process wherein a gasiform hydrocarbon material is contacted with a iiuidized mass of nely divided catalytic solids in a reaction zone and the reaction products thus produced are substantially separated from said fluidized mass and leave the reaction zone containing a small amount of entrained catalyst fines relative to the quantity of catalyst which is present in the reaction zone, the improvement which comprises cooling the hot gasiform mixture of reaction products and entrained catalyst fines sufficiently to condense a major portion of the normally liquid fraction of the products boiling above the gasoline range, scrubbing catalyst nes out of the uncondensed gasiform products by contact with the high-boiling condensate to form a slurry, settling said slurry, decanting a catalyst-free portion of the highboiling condensate from the settled slurry, recycling a catalyst-containing portion of the settled slurry to the conversion reaction in a manner whereby the period of residence in the reaction zone is substantially shorter than the aforesaid gasiform hydrocarbon material, cooling the uncondensed gasiform products sumciently to condense a major portion of the normally liquid products therein boiling within the gasoline range, stripping a normally liquid fraction boiling within the gasoline range from the decanted high-boiling condensate by reducing the pressure thereon and by contact with a portion of the uncondensed remainder products whereby the remainder products are enriched, and contacting the enriched remainder products with the liquid hydrocarbon feed for the conversion process to absorb therefrom the normally liquid fraction boiling within the gasoline range.

4. In the refining ci' the products of a catalytic hydrocarbon conversion process wherein a gasiform hydrocarbon material is contacted with a fluidized mass of finely divided catalytic solids in a reaction zone and the reaction products thus produced are substantially separated from said fluidized mass and leave the reaction zone containing a small amount of entrained catalyst nes relative to the quantity of catalyst which is present in the reaction zone, the improvement which comprises cooling the hot gasiform mixture of reaction products and entrained catalyst nes sufficiently to condense a major portion of the 'normally liquid fraction of the products boiling above 'the gasoline range, scrubbing catalyst nes out of the uncondensed gasiform products by contact with the high-boiling condensate to form a slurry, settling said slurry, decanting a catalyst-free portion of the highboiling condensate from the settled slurry, recycling a catalyst-containing portion of the settled slurry to the conversion reaction in a manner whereby the period of residence in the reaction zone is substantially shorter than the aforesaid gasiform hydrocarbon material, cooling the uncondensed gasiform products sufciently to condense a major portion of the normally liquid products therein boiling within the gasoline range, stripping a normally liquid fraction boiling within the gasoline range from the decanted high-boiling condensate by reducing the pressure thereon and by contact with a portion of the uncondensed remainder products whereby the remainder products are enriched, and contacting the enriched remainder products and another portion of the uncondensed remainder products with the liquid hydrocarbon feed for the conversion process to absorb therefrom the normally liquid fraction boiling within the gasoline range.

EVERETT W. HOWARD.

JOHN B. OSBORNE.

HENRY P. WICKHAM.

References Cited in the le of this patent UNITED STATES PATENTS Number Name Date 2,166,177 Peterkin July 18, 1939 2,313,940 Hirsch Mar. 16, 1943 2,449,096 Wheeler Sept. 14, 1948 

1. THE REFINING OF THE PRODUCTS OF A CONTACT PROCESS FOR THE CONVERSION OF HYDROCARBONS WHEREIN A GASIFORM HYDROCARBON MATERIAL IS CONTACTED WITH A MASS OF FINELY DIVIDED SOLIDS IN A REACTION ZONE AND THE REACTION PRODUCTS THUS PRODUCED ARE SEPARATED SUBSTANTIALLY FROM SAID MASS OF SOLIDS AND THEREAFTER CONTAIN A SMALL AMOUNT OF ENTRAINED SOLID FINES RELATIVE TO THE QUANTITY OF SOLIDS PRESENT IN THE REACTION ZONE, THE IMPROVEMENT WHICH COMPRISES COOLING THE HOT GASIFORM REACTION PRODUCT AND ENTRAINED SOLID FINES TO CONDENSE A MAJOR PORTION OF HIGH BOILING NORMALLY LIQUID PRODUCTS, SCRUBBING THE SOLID FINES OUT OF UNCONDENSED GASIFORM PRODUCTS TO FORM A SLURRY, SETTLING SAID SLURRY, DECANTING A SUBSTANTIALLY SOLIDS-FREE PORTION OF THE HIGH BOILING CONDENSATE FROM THE SETTLED SLURRY, COOLING THE UNCONDENSED GASIFORM PRODUCTS SUFFICIENTLY TO CONDENSE A MAJOR PORTION OF RELATIVELY LOWER BOILING NORMALLY LIQUID PRODUCTS THEREFROM THUS LEAVING UNCONDESED NORMALLY GASEOUS PRODUCTS, STRIPPING LOWER BOILING NORMALLY LIQUID PRODUCTS FROM THE DECANTED HIGH BOILING CONDENSATE BY REDUCING THE PRESSURE AND BY CONTACTING THE SAME WITH A PORTION OF NORMALLY GASEOUS PRODUCTS WHEREBY THE LATTER PRODUCTS ARE ENRICHED, AND CONTACTING THE ENRICHED NORMALLY GASEOUS PRODUCTS AND ANOTHER PORTION OF THE NORMALLY GASEOUS PRODUCTS WITH THE LIQUID HYDROCARBON FEED MATERIAL FOR THE CONVERSION PROCESS TO ABSORB THEREFROM RELATIVELY LOWER BOILING NORMALLY LIQUID PRODUCTS BY ABSORPTION. 